Means for locating and retaining ferrule portions of terminals and connectors in crimping dies



EAOZASE F. J. MRAZ MEANS FOR LOCATING AND RETAINING FERRULE PORTIONS OFTERMINALS AND CONNECTORS IN CRIMPING DIES 5, 1966 2 Sheets-Sheet 1 FiledApril 2 INVENTOR. FRANK J. MRAZ ATTORNEY Sept. 24, 1968 F. J. MRAZ3,402,452

MEANS FOR LOCATING AND RETAINING FERRULE PORTIONS OF TERMINALS ANDCONNECTORS IN CRIMPING DIES Filed April 25, 1966 2 Sheets-Sheet 2 FIG.4

INVENTOR. FRANK J.MRAZ

ATTORNEY United States Patent MEANS FOR LOCATING AND RETAINING FER- RULEPORTIUNS OF TERMINALS AND CONNEC- TORS IN CRIMPING DIES Frank J. Mraz,Euclid, Ohio, assignor to ETC Incorporated, Cleveland, Ohio, acorporation of Ohio Filed Apr. 25, 1966, Ser. No. 544,763 3 Claims. (Cl.29--2t 3) ABSTRACT OF THE DISCLOSURE A clamp for locating andpositioning the ferrule portion of electrical terminals and connectorswithin a crimping die prior to a crimping operation. The clamp includesa pair of opposed clamping members, each of which has its own biasingmeans for urging a clamping surface into engagement with a portion ofthe terminal and connector which projects axially from the die surfaces.The clamps permit axial and non-axial movement of the connector duringthe crimping operation.

This invention relates to devices for locating a Workpiece and, moreparticularly, to a device for positioning the ferrule portion of aconnector relative to a set of crimping dies and relative to the end ofan electrical conductor prior to the attachment of the connector to theconductor by a crimping operation.

The invention is particularly concerned with applications involving thejoining of either insulated or noninsulated, solderless electricalconnectors to stranded and solid wire conductors for the purpose ofeither terminating the conductors or connecting them to otherconductors, such joining being carried out by the known generalprocedure of telescoping a tubular ferrule portion of the connector overthe bared conductor and then coldforging the elements into electricaland mechanical union. Such connectors may be, for example, any of theclass comprising a tubular metal ferrule having any of a variety ofaxially projecting tongues or sockets, or the like at one end thereoffor terminating a conductor at a panel or terminal block, or the like,or for receiving a mating part on the end of another conductor. Theyalso may be, for example, any of the class comprising a tubular metalferrule and projecting end portions, such as ring tongue, spade tongue,hooked tongue, rectangular tongue, and flanged spade end portions.

As will be made more apparent, the same novel workpiece locating deviceto be hereinafter described may be used to advantage with both insulatedand non-insulated connectors.

Typical procedures which have been employed in the past to crimppre-insulated or uninsulated connectors to insulated or uninsulated wireconductors are characterized by either (a) prepositioning the connectoron the conductor by first telescoping the tubular ferrule portion of theconnector over the bared conductor and then positioning the looselyassembled elements in the female portion of a crimping die, or (b) firstinserting the tubular ferrule portion of the connector in the crimpingdie and then inserting the bared conductor into the pre-positionedtubular ferrule portion of the connector. These procedures involveprecise positioning operations and often result in a crimped assemblyhaving a conductor protrud- 3,4a2,45z Patented Sept. 24, 1968 ice ingtoo far beyond the ferrule portion of the conductor, or in a crimpedassembly having a conductor extending only partially into the ferrule.If the conductor projects too far beyond the end of the ferrule in suchan assembly, the end or ends of the conductor may cause shorting orarcing, or may prevent the connector from mating properly with anotherconnector. If the conductor extends only partially into the ferrule, apoor electrical and mechanical connection results. Attempts have beenmade to properly position a connector in a pair of crimping dies byproviding stop or positioning mechanisms on one of the dies. Suchpositioning machanisms often include a spring-biased clamp which engagesa portion of the connector and resiliently clamps a portion of theConnector against a rigid surface.

According to the present invention, a work locating device includesclamping surfaces which engage opposite portions of the connector andthese clamping surfaces are independently biased into engagement withthe connector. This arrangement permits the axial and non-axial movementof the connector as the connector is being coined onto its conductor.Moreover, such an arrangement facilitates the initial positioning of theconnector relative to the dies, since both clamping surfaces may bemoved to accommodate the insertion of the connector between suchclamping surfaces.

An object of the present invention is to provide a device forresiliently clamping an electrical connector in a predetermined positionrelative to a pair of crimping dies prior to a crimping operation, whichdevice includes independently biased clamping surfaces which engageopposite portions of the connector to locate the connector relative tothe die surfaces prior to the crimping operation and to permit axial andnon-axial movement of the connector during the crimping operation.

t is a further object of the present invention to provide a device whichwill accomplish the above object while properly locating the conductorrelative to the connector prior to the crimping operation.

Other objects and advantages of the invention will become apparent fromthe following detailed description and the accompanying drawings.

In the drawings:

FIG. 1 is an elevational view of a pair of opposed crimping diesprovided with a locating device according to the present invention,showing the dies in an open position with a pre-insulated terminalconnector correctly positioned in the lower die;

FIG. 2 is a sectional view of the device, the plane of the section beingindicated by the line 2-2 in FIG. 1 and showing an insulated conductorwhich is about to be inserted into the open end of the connector;

FIG. 3 is a sectional view of the device, the plane of the section beingindicated by the line 3-3 in FIG. 2;

FIG. 4 is a plan view of the device, the plane of the view beingindicated by the line 4-4 in FIG. 1; and

FIG. 5 is a fragmentary, sectional view, similar to FIG. 2 but showingthe device employed to locate a dilferent type connector.

Referring now to the drawings, a set of opposed, upper and lowercirmping dies 10 and 11, respectively, is illustrated. The illustratedset of dies may be mounted in a suitable hand or power-actuated crimpingtool or apparatus (not shown). It is to be understood that the diesillustrated herein are shown merely as an example. Other dies,

such as dies attached to hand crimping tools, may be provided with thedevice according to this invention.

The dies and 11 are illustrated as crimping a conventional terminalconnector 20. The illustrated terminal connector is of the usualconstruction and comprises a cylindrical ferrule portion 21 and anattached tongue 22 adapted to cooperate with a binding post or the like.As is known to those skilled in the art, the connector 20 may be stampedfrom a fiat sheet of malleable, electrically conductive material, suchas, for example, copper or a copper alloy, steel, aluminum, and thelike, into a shape having oppositely extending ear portions which arethereafter rolled or bent into edge abutment to form the ferrule 21.

The terminal 20 is shown insulated in a known manner by a sleeve 23 ofelectrical insulating material which is telescopingly mounted around theferrule 21. The sleeve 23 may suitably be formed from any of a number ofdifferent plastic materials possessing the desired insulating qualitiesand which resist fracture during cold deformation.

In the formation of crimped electrical connections, the hated end 24 ofa conductor is positioned within the connector ferrule 21, which is thencrimped to the conductor end to form a uniform, solid mass. Theconductor 25 may be stranded as shown, or a solid conductor, or both,i.e., a heavy, solid conductor surrounded by a number of smallerstrands.

The upper die 16 includes a first portion 12 for crimping the ferrule 21of the connector 20 onto the bared conductor end 24 and second portion13 for crimping the insulating sleeve 23 of the connector 26 onto theinsulation of the conductor 25. Similarly, the lower die 11 includes afirst portion 14 for opposing the portion 12 and crimping the ferrule 21of the connector and a second portion 15 for opposing the portion 13 andcrimping the insulating sleeve 23 of the connector 20 onto theinsulation of the conductor 25.

The portion 12 includes a female die nest or matrix 16 and the portion14 includes a male die member 17 which is movable into cooperation withthe matrix 16 to pcripherally confine the ferrule 21 of the connector 20during the crimping operation. The matrix 16 and the male die member 17have concave die surfaces 18 which contact the ferrule 21 of theconnector 215 and perform the ferrule crimping operation. It is to beunderstood, however, that the die surfaces 18 may have any suitableconfiguration for crimping.

The portion 13, similarly, includes a female die nest or matrix 19, andthe portion 15 includes a male die member 26 which is movable intocooperation with the matrix 19 to peripherally confine the insulatingsleeve 23 of the pre-insulated connector 20 during the crimpingoperation. The matrix 19 and the male die member 26 have concave diesurfaces 27 which contact the insulating sleeve 23 of the connector andperform the operation of crimping the sleeve 23 onto the insulation ofthe conductor 25. It is to be understood, however, that the die surfaces27 may have any suitable configuration for crimping.

A work locating device 30 is fixed to the first portion 14 of the lowerdie 11 by a screw 31. The device 30 includes an upper clamping member 32and a lower clamping member 33 which are nested together and areslidably received in a casing 34. The clamping member 32 is C- shapedand has a pressure pad 35, a vertical leg 36, and a horizontal leg 37.Similarly, the member 33 is C-shaped and includes a pressure pad 38, avertical leg 39, and a horizontal leg 40. The casing 34- is C-shapedand, together with a plate 41, defines a housing for the upper and lowerclamping members 32 and 33. A first coil spring 42 is fixed at one endto a spacing bushing 43 and biases the lower clamping member 33upwardly. A second coil spring 44 is fixed at one end to the bushing 43and biases the upper clamping member 32 downwardly. Thus, the upper andlower clamping jaws are independently biased to provide an effectiveclamp and to provide a clamp which will permit upward or downwardmovement of a clamped article.

As is shown in FIG. 2, the tongue 22 of the cylindrical ferrule portionis clamped by the members 32 and 33 of the device 39. The connector 20is easily inserted into the clamp by lifting a projecting end 3511 ofthe clamping member 32 and inserting the tongue 22 between the separatedmembers 32 and 33. When the connector 20 has been properly positioned onthe die members 17 and 26, the upper clamping member 32 is released tosecurely hold the connector 26 in its proper crimping position. With theconnector 26 properly positioned in the foregoing manner, the bared end24 of a conductor 25 is inserted into the ferrule 21. The pressure pad35 of the upper clamping member 32 acts as a wire stop to preventovertravel of the bared end 24 within the ferrule 21.

During the ensuing crimping operation, the connector is coined onto thebared end 24 of the conductor 25. During this crimping operation, theconductor may extrude axially and such axial extrusion is permitted byslippage between the clamping members 32 and 33 and the tongue 22. Theconductor may also tend to move upwardly or downwardly and this movementis permitted by the upper and lower clamping members 32 and 33, thuspreventing any jamming of the connector 29 in the dies.

A particularly advantageous feature of the device 3% is that the devicemay be employed to locate connectors other than connectors of the typeillustrated in FIG. 2. Referring to FIG. 5, a splice connector isillustrated. The connector St is employed in splicing the conductor 25to another conductor and includes ferrule portions 51, an insulatingsleeve 52, and a transverse indentation 53 in the sleeve 52. The upperclamping member 32 and the lower clamping member 33 locate the connector50 in a proper position on the die members 17 and 26, with the upperclamping member 32 nesting in the indentation 53.

The invention is not restricted to the slavish imitation of each andevery one of the details described above, which have been set forthmerely by way of example with the intent of most clearly setting forththe teachings of the invention. Obviously, devices may be provided whichchange, eliminate, or add certain specific details without departingfrom the invention.

What is claimed is:

1. In combination with a plurality of relatively movable dies having diesurfaces for crimping ferrule portions of terminals and connectors toelectrical conductors, a device for locating the ferrule portions ofsuch terminals and connectors relative to the die surfaces prior to acrimping operation, comprising means axially spaced from said diesurfaces and defining clamping surfaces for engaging opposite portionsof said terminals and connectors which project from said die surfaces,each of said clamping surfaces haviag its own biasing means, and eachbiasing means urging a clamping surface into engagement with saidopposite portions of said terminals and connectors to locate the ferruleportion of said terminals and connectors relative to the die surfacesprior to a crimping operation and to permit axial and non-axial movementof the terminals and connectors during the crimping operation.

2. The combination according to claim 1 wherein the locating deviceincludes first and second C-shaped clamping members, each of theC-shaped clamping members having a pressure pad, a vertical leg, and ahorizontal leg, said C-shaped members being slidably mounted in a casingwith the horizontal leg and the pressure pad of the first clampingmember being respectively positioned under and over the horizontal legand the pressure pad of the second clamping member.

3. The combination according to claim 1 wherein the device includesfirst and second C-shaped clamping members, each of the C-shaped membershaving a pressure pad, a vertical leg, and a horizontal leg, saidC-shaped members being slidably mounted in a casing with the horizontalleg and the pressure pad of the first clamping member being respectivelypositioned under and over the horizontal leg and the pressure pad of thesecond clamping member, a first spring urging the pressure pad of thefirst clamping member toward the pressure pad of the second member and asecond spring urging the horizontal leg of the second clamping membertoward the horizontal leg of the first clamping member.

6 References Cited UNITED STATES PATENTS 1,084,218 1/1914 Mayo 29-2l11,084,219 1/1914 Mayo 29-211 2,256,428 9/1941 Green 29417 2,409,147 10/1946 Neuhaus et a1 29-203 3,327,375 6/1967 Reijnhard et a1 29-203 THOMASH. EAGER, Primary Examiner.

